Composition shingle and roof formed therewith



March l1, 1941. 'rg G, MURPHY 2,234,446

COMPOSITION SHINGLE AND ROOF FORMED THEREWITH Filed July 29, 1940 e fff'fb 1 :Zim

if i274' 34 I 235 26 31a im 2 Sheets-Sheet l March 11-, 1941. T( G,MUR-PHY 2,234,446

COMPOSITIION SHINE-LE .AND ROOF FO'RMED THEREWITH Filed July 29, 1940 l2 Sheets-Sheet 2 y, e I l O 9' .10. al I o 61 /727 w. 80 y2 f SWW/Wto@Parenteel Mer. 11, 1941 ooMPosrrroN smNGLE AND noor FOBMED THEREWITH'rneephuue Gregory Murphy, LosAngeles, oeuf. Application July ze, i940,sei-1eme. 348,321

This invention relatesto'composition shingles and pertains moreparticularly to an individual" composition shingle and the with. I 5 Aparticular object of the invention is to provide an individualcomposition shingle of pleasing appearance and with enhanced wearcharacteristics.

A further object of the invention is to provide an improved compositionshingle roof.

The composition material referred to herein is meant to include thematerial commonly used for roong purposes. l

It is the custom nrst to form a base sheet of felt which is madeordinarily ofl rag iibers or rag and asbestos fibers or the like, of thederoof formed theresired thickness and of suilcient porosity'to perwiththe bituminous saturating compound, either by immersion in a bath ofamolten bitumen or pitchy or by subjection to "pressure saturation,

the sheet is coated on one facewith a fairly thin layerof highmelting-point asphalt. For this purpose, oxidized or so-called blownasphalt is preferably employed because of its tough and rubbery nature.While .the asphaltic coating is stillsoft and plastic and before it hasset, it is surfaced with any suitable form of `crushed minl era-l suchas crushed slate. tile or any other mineral gritwhich willy impart thedesired color and texture to the nal product. f

'I'he grit is preferably formed in relatively large particles orgranules which vary in form according to the material from which theyare produced. The surface mineral coating is partially embedded inthe'plastic asphaltic coating su'lciently to insure a rm interlocking ofthe granules with the asphaltic coating, but leaving.

the granules so exposed that the asphaltic layer is completely coveredand masked bythe particles or grains of grit. Y

The' sheet .thus formed, a'nd ordinarily called mineral-surfaced orslate-surfaced rooting, is,

now cut intoroong .elements which take the form of'individual shingles.In general, all of the edges of such a shingle will expose theedge 55,ofthe felt andthe asphalt layer. In laying a (ci. ros-t) V roof`according to my invention, as will-subse- I quently be described ingreater detail, the shingles will be laid in overlapping courses and'.in overlapping relation in each course in such manner that side andbottom edge portions of 5 the shingle will be exposed to the elements,this method of laying being commonly referred to as the Dutch lap"method. Thus these .exposed edge portions will be subject to mechanicalstress and to the weather. The asphalt exposed 10 to the elements and tothe sunlight is susceptible to rapid deterioration. This is especiallytrue of the asphalt or other bitumen which is utilized as a saturatingcompound for the foundation felt inasmuch as these mms-about the bers of.15 the felt are relatively thin. Dueto the" action of the light andoimoisture, these illms crumble; and this, together with the absorptiongol.' moisture by the exposed fibers, causes a. breaking. down of theexposed edges and produces a tend- 20 ency on the part .of the exposedmargin of the roofing element to curl. The curling is doubtless alsoaccelerated by the fact thatthe layer of coating asphalt contracts underthe inuence' of the elements 'and therays o! the sun and be- 25- theDutch 1an method is that, when rain :aus '30 on the roof, the water runsdown over the surfaces of the shingles in" close proximity. tol theexposed side edges oi' the overlapping side portionsof adjacent shinglesand tends to ilow `or .creep under these overlapping side portions and35 thus leak through the root, and the leakage of water beneaththese-overlapping side edgesis. increased by the action of wind 'inblowing the water toward and under these overlapping side edge portions.A

The principal object ot the present invention ir. to provide an improvedcomposition shingle adapted forlayingby the Dutch lap method, and an.improved composition shingle -roof laid by this method, in which theabove-mentioned objectionable features areeffectively overcome. In thisconnection, a. particular object isto-protect the body portion of .theshingle (including the saturated sheet and its surface coating) 'fromexposure to thedeteriorating action o i.' weather 50 andsunlightatthefexposedside and bottom'v edges'of the-shingle. Ano erimportant object is to substantially prevent f leakage of water of theshingles.'

A further object of the invention is to provide an individualcomposition shingle with its exposed edge portionsncl'osed in anasphaltic en-A velope. Y

Another object of the invention is to provide an improved shingle roofformed with individual composition shingles according to this invention,the roof being laid with a plurality of courses and being secured to theroof in such manner that the fastening means is protected from theweather and the individual shingles are secured to one another.

A further object of the invention is to provide an improved roof usingcomposition shingles having thickened exposed marginal portionsaccording to this invention, 'whereby the thickened portions act asgutters to conduct draining 'moisture away from the joints betweenshingles.

I accomplish the above and other objects of the invention by enclosingthe above-mentioned exposed edge portions and the marginal portions ofthe exposed side portions of an individual composition shingle in acontinuous envelope of asphaltic material. To protect this envelope fromthe action of the sunlight a layer of mineral granules, preferably ofcontrasting color to the surface coating of granules, is partiallyembedded therein.

My preferred shingle has an outline corresponding generally to anon-rectangular parallelogram, and, when laid in` accordance with mypreferred procedure,the exposed bottom edge-portion extendssubstantially horizontally and the exposed lateral edge portion extendsat. an obtuse angle with respect to said bottom edge portion and thus atan angle to the path followed by rain and other liquids draining fromthe roof. The'asphaltic envelope increases the thickness of the shingleat its exposed lateral marginal portions and rises above the plane ofthe upper face of the shingle to form a wall which acts as a gutter toprevent liquids from draining over the lateral edge of the shingle intothe joints between shingles, as will be described more fullyhereinafter. When the shingles are shaped and laid in accordance with mypreferred practice, the exposed lateral edge portionslextend at an angleto the path followed by liquids draining from the roof and the gutteraction is further improved. z A

. Further objects and advantages of my invention will be apparent as thedescription proceeds.

' I have illustrated my invention in the accompanying drawings, inwhich:

Fig. 1 is a plan view of an individual composition shingle constructedaccording to this invention;

Fig. 2 is a sectional elevation of one of the mentA which may be used toform a shin le according to my invention showing a shingle in vdifferentpositions during the process in dotdash lines; Fig.5 is a plan view of ashingle illustrating the process of rolling the edges as viewed alongline 5 5 in Fig. 4;

Fig. 6 is another view thereof taken along line ss1nFig.4; M l

Figs. 7 throughv l0- illustrate diagrammatically thesteps of shingling aroof according to the "Dutch lap method with shingles according yto thisinvention.

Fig. l1 is a plan view of a portion of a roof laid in accordance withthe principles described in connection with Figs. 7-10 and usingshingles according to this invention; and

Fig. 12 is a view partly in section and partly in elevation taken alongline I2-I2 in Fig. l1, illustrating the type of joint obtained whenshingles are laid in accordance with this invention.

Referring to Figs. 1-3, an individual shingle according to thisinvention is shown to have an outline generally in the form of anon-rectangular parallelogram. .The edges meet at obtuse angles atdiagonally opposite corners and at acute angles at the remainingcorners. The shingle I0 may be constructed from common compositionrooiing material, as above described, which comprises a base layer I Iofrag orasbestos roofing felt properly impregnated with asphalt or othercommonly used waterproofing compound. The front face of the base layerII is provided with a thin layer I2 of higher melting point asphaltwhich bonds to the base layer II and acts as a matrix to hold a layer ofrooilng granules I2al.

Sides I3 and I4 of the shingle meet at an obtuse angle and, as will beexplained more fully j hereinafter, portions of these sides are exposedwhen the shingle is laid in accordance with my preferred procedure. Theexact obtuse angle used is not critical, but an angle of about issatisfactory. Since the shingle has thickness, edges I3a and Ila,corresponding to sides I3 and I 4 respectively, will of course beexposed to the weather for the same distance that the sides are exposedwhen the shingle is laid. Protection of these edges is of primaryimportance.

The exposed portion of lateral edge Iiia of the shingle (theshinglebeing shown in its common position for laying in Fig. 1) and the exposedportion of bottom edge Ila of the shingle are provided with coatings ofasphalt or other suitable material as at I5 and I5a which are firmlybonded with these edges and with the marginal portions of the front andrear faces of 'the shingle adjacent the sides I3 and I4, to-.form acontinuous asphaltic envelope encasing the ex-l tively which are in turnbonded with the layers I5 and I5a. respectively and are preferablypartially embedded therein. Since the length of the exposed lateral sideis usually somewhat shorter than the length of the exposed bottom side,and

' for artistic reasons, I prefer to provide a wider marginal coating forthe bottom side than for the lateral side, asmay be seen by antnspection of Figs. 1, 2 and 3. I

In constructing shingles in accordance with this invention, they areordinarily first cut in any convenient manner, as by means of machines.

provided for this purpose, from rolls of common roofing material, sincethis material is readily obtainable. Although the exact size of theshingle may be varie'd over rather wide limits, I find a width of aboutone foot as measured between the top and bottom edges, and a length ofabout one and one-half feet 'as measured along the bottom edge,suitable. A

`To form the reinforced edges of the shingles with the utmostconvenience, a' form of apparatus such as shown in Fig. 4 may beutilized. This troughs are adapted to hold quantities and 26 oi suitablegranular mineralmaterlal.

Outwardly of these troughs are located work tables 21 and 28 providingplane surfaces for supporting shingles during the operation of rollingthe reinforced edge portions in a manner to be described subsequently.Obviouslyv a. single work table and sand trough, when used inconjunction with the asphalt trough, is suillcient to practice thisinvention. However, it is preferable to 'construct the apparatus in themanner illustrated in order to provide space for workmen on each side ofthe trough 22.

In practicing my invention, a blank fo'r an individual shingle, eitherformed as described above or formed by other means, is rst dipped withits lower or bottom edge, for example, to a desired depth, say aboutfive-eighths of an inch, below the surface 22 of the molten asphalt,which is maintained at a temperature of about 500 F.

'I'he shingle, indicated in dot-dash lines at Sia,v is preferablymaintained in a vertical position' during this step. After the shinglehas remained in the position indicated at 31a for a few seconds so thatthe waterproong material in the base layer. ll and the asphalt layer|211 will soften and bond firmly with the coating formed by the asphaltin the tank 20, the shingle is then turned in the position indicated indot-dash lines at 3lb to dip the exposed side edge in the moltenasphalt. The exposed lateral edge is preferablyy impregnated for ashorter'distance than the exposed bottom edge. For example, the lateraledge gay be immersed to a depth of about one-quarter In order tomaintain uniformityin the finished shingles, the trough 23 is preferablyprovided with a shelf 32 having a central portion 33 which is located ata4 greater depth below the surface 22 than its outer portions 34 and 33.Thus when dipping the bottom edge of the shingle it is rested on thecentral portion 33 ofthe shelf, and when dipping the lateral edge it isrested on one of the lateral edgeportions such as the portion 3s.

The position of the shingle during dipping of its lateral edgeisf'preferably vertical as indicated in dot-dash lines at 3th. I'helateral edge is dipped for substantially the same length of time as thelbottom edge, and the temperature of the molten asphalt is preferablysui'ssi'fantiall'y the same as the temperature oi the asphalt in whichthe bottom edge was dipped.

and then the, other of .the coated edge portions is inserted in thegranule trough 23 in contactwith the roof-lng granules 2S while thecoating formed is soft and plastic. The shingle is preferably heldvertically when in the granule trough, as indicated in dot-dash lines at3io, and if any motion is imparted to the shingle this motion isl Artel-'alppmg in the granules the shingle is 6 laidwith itsback face downagainst a ilat'surface such as afforded by the table 21, as indicated infull lines' at Sid. 'I'he upper and outer faces of the reinforced edgeportions are then sub- .lected to a rolling operation to smooth thesefacesI and force the granules to partially embed in the coatings.

.A roller which I have found useful for this pur- -pose is shown ascomprising a pair of rollers Il and 42 mounted with their axessubstantially horizontal on a suitable frame member 42 which is providedwith a handle portion M. The miler is further provided with a third roll45 which is mounted on the frame 43 with its airis generally 2perpendicular to the axis of the rolls 4i and t2.

I'he bottom and lateral marginal portions of the shingle tlc which havebeen provided -with the reinforcing coating are designated d6 and 41respectively. The rollers 4| and Q2. are adapted to press verticallydownwardly on the upper sides of these coated faces to firmly bond theroong granules with this coating. The other roller 45 bears inwardly onthe coating portion covering the edges. The roller is preferably given amotion toward the meeting corner 48 of the two coatings. Thus the rolleris applied in the direction of the arrow A on the lateral marginalportion 41 and in the direction of thearrow B on the bottom marginalportion. After thorough rolling and after the coating has cooledsumciently, the shingle is ready for use.

The `above-described individual composition .shingle is particularlyadapted for shingling a roof in accordance with the Dutch lap method.

This method is outlined diagrammatically in @o Figs. 'I-lO. In thesefigures the numeral Si) designates the lower left-hand corner portion ofa roof having a left side edge 6| and a lower edge 62.. A first shinglelila is laid in the lower lefthand corner of the roof.. This shingle maybe the same as the shingle l0 shown in Figs. 1-3. and is trimmed alongits left side so that it will lie with its bottom edge substantiallyalong a horizontal line and parallel to the bottom edge 52 of the roofand with its left side edge parallel to the side edge 3l ofthe roof. Theshingle Wa is secured in position by'means of roofing nails t3 and '84located in the upperleft and-lower right-hand corners of the shinglerespectively. 5F

lap of approximately two inches. for th sides of shingles in asinglecourse is satisfactory. The top and bottom'edges of thisshingle arealined with the top'and bottom edges-of the shinglev ita. The -shinglellib is no w secured in position by means of a roofing nail in its upperlefthand corner which also passes through the portion ofthe shinglelilaiying below the shingle illb. A roofing nail 68 is also placed inthelower right-hand corner of the shingle illb. y

A third shingle l0c is now laid overlapping the 7 shingle Iilb inexactly the same mannerthat thev shingle'lb was laid to overlap theshingle lila". Shingle Ille isrsecured by means of roofing nails 61 and88 in its diagonally opposite upper lefthand corner and lower right-handcorner' as at 7 6l and 88. This process vis continued until thelowermost course of shingles has been laid. Al

second course of shingles is now laid above the lower course insubstantially the same manner as the shingles are laid in the lowercourse. The second course is laid overlapping the first course by anamount which is about equal to the amount that the shingles overlap oneanother inthe respective courses.

Referring now to Figs. 9 and 10, a first shingle I Dd in the secondcourse is trimmed in a manner Alaid with its bottom edge forming acontinuation of the bottom edge of the shingle Ind and overlapping theshingle ld by substantially the same amount as the shingle |0b overlapsthe shingle Illa. The shingle Ille is held in place by means of roofingnails 13 and I4 in the diagonally opposite corners.

The third shingle I 0f in the second course is laid in exactly the samemanner as the shingle Ille and overlaps this shingle and is held inplace by means of roofing nails 15 and 18. This process is continuedtill the second course is completed. Subsequent courses 'are added inthe same manner until the roof is brought to its uppermost extremity atwhich point the roof is completed in accordance with common roofingpractice. Suitable means such as strips of wood,l met-al or compositionmaterial is usually provided along the side and bottom edges of the roofto hold the shingles flrmly in position to prevent the entrance ofmoisture and to lessen the effects of the wind.

An inspection of Figs. 7-10 will show that each individual compositionshingle is held in place by -four roofing nails. For example, theshingle lllb is held in place by means of nails 65, 66, 81, and .14. Itwill also be noted that when the roof is completed none of the nails areexposed tothe weather since they are all covered by the shingles. Inpractice the surface occupied by the nails is covered with an adhesivec'ementing material which protects the nails from the Weather and alsoserves to hold down `the lower left-hand corner of each of the shingles,as will be described more fully in conr. action, with Figs. 11 and ,12.

Referring to said figures, a portion of a roof 8l shingled in accordancewith the method out- -lined in Figs. 7-10 is indicated at 19. Theindividual shingles 80 forming the roof m-ay be constructed in the samemanner as the shingle Il)A the lower unsecured corner of each of theshingles is lifted and a layerof waterproof adhesive cementing materialis placed beneath the lower'face of thevshingle at this corner and be-'of the shingle. pointed out that the coatings need not extend for neaththe marginal portions of the exposed lat- I eral andv bottom sides for asufficient distance to cover` `the nails which lie beneath -these sides.One of the shingles, indicated at a, is shown with its lower unsecuredcorner lifted to show how the layer of cementing material 86 isapplied.4 After this layer 85 of adhesive cementing material is applied,the lower cornery 85 of the shingle is pressed down against this layerto secure this shingle to the shingle beneath it and to completelyprotect the nails from the Weather.

The coated edge portions 8| and 82 of the shingle reinforce it andgenerally increase its mechanical strength, particularly they lessen thetendency of the shingle to rip along its edges. At the same time theadded weight and strength along the edges and the marginal portions ofthe front and rear faces along these sides reduce the tendency of theshingle to curl after it is applied. Coupled with this-mechanicaladvantage, these coatings protect the edges of the felted backing layerand prevent drying out of the waterproofing material and also lessen thetendency of the shingle to curl. This protective envelope also preventsthe entrance of moisture into the edges In this connection it shouldv bethe full length of the lateral and bottom edges and may be omitted onthe portions of these edgeswhich are overlapped by other shingles.

The reinforcing layer 8| extending along the.

lateral margin of the shingle performs an added function by virtue ofthe fact that it rises above the plane of the shingle, vas may be seenby inspection of Fig. 12 and as indicated at I6 in Fig. 2. In otherwords, the shingle is thickened along its lateral side. This layer actsas a gutter to prevent liquids from draining over-the ing. IWithout theraised lateral edge portion, this liquid would tend to run over thelateral edge where it would be blown into, or otherwise caused topenetrate, the overlapping side joint to the left of the shingledisplaying the drainage lines will drain away from the overlappingjoint.

Obviously my invention is subject to some modiilcation, hence I do notchoose to be limited lto the above-described examples, but rather to thescope of the appended claims.

I claim:

1.` As an article of manufacture, an individualcompositionshinglecomprising: a sheet of composition rooflng materialhaving an asphaltic coating and a layer of partially embedded granularmaterial on one face thereof, said sheet having an outline generally inthe shape of a parallelogram with-two ofl its sides meeting at onecorner at an\obtuse angle, said shingle being adapted for laying inaccordance with the Dutch lap method whereby said corner andl portionsof said sides are exposed; and a reinforcing coating of granular'material partially embedded in asphaltic material covering the ex- 2.An individual shingle adapted to be laid with others in overlappingcourses so as to have exposed bottom and lateral edge portions,vcomprising a felted foundation impregnated with a waterproong material;a coating of asphalt on the exposed face of said foundation; alayer ofgranular material attached to said coating; a

continuous envelope of asphalt encasing said exposed bottom and sideedge portions; and a layer of granular material 'partially embedded insaid envelope of asphalt. 'l

3. An individual shingle having an outline substantially ofv aparallelogramwith two adjacent sides disposed at an obtuse angle, saidshingle being adapted for laying with others in overlapping courses,whereby portions of said sides are exposed, said shingle comprising: afelted foundation impregnated with waterproofing material; a layer ofasphalt' on the top of said foundation as laid; a layer of granularmaterial .partially embedded in the top yof said asphalt; another layerof asphalt extending along said exposed side portions and over a smallpart of the top and bottom faces of said foundation; and another layerof granular material partially embedded in said other asphalt layer.

4. An individual shingle of composition roofing material, having anoutline substantially of a non-rectangular parallelogram with twoadjacent sides disposed at an obtuse angle, said shingle having anadditional coating of asphalt with a layer` of granular materialpartially embedded of substantially horizontally extending courseswith.l each upper. course overlapping a lower course, the shingles ineach of said courses being laid with a corner at which the sides meet atan obtuseangle disposed toward the, bottom and one side of the roof andoverlapping the next shingle in that course located nearer to said sideof the roof, each of said shingles being thickened at the exposed edgeportions of said sides which meet an obtuse angle, wherebyliquidsdraining from said shingle are guided by one of said thickenededge portions away from the adjacent overlapping joint. l

roof and located near the corners gle which meet at acute angles.

7. A roof as set forthk inclaim `5, the overlap-.v ping shingles ineach-course beingsecured to",

one another by a layer `of cementing AmaterialA located beneath saidcorner.v Y Y" Y 8. A roof asset forth in claim 5*, the shingles in onecourse 'beinglaid with their lower edge' overlapping the uppergedge.of'shlngles in thel next lower course and with one side edge abuttingthe side edge of` a'. shinglein..said -loi1ver v 1.-

9. A shingle roofl comprising; a plurality of` shingle'v COUTS@-substantallyhorizontally extending ,courses with each. upper courseoverlapping ,al

lower course, the shinglesi'n each ofrsaid ooursesg ,20 I I A.

being laid progressively gfromonefs'ide of the roof to the otherin-"overlappinggrelation; -each f of said shinglesghaving substantiallytheoutline"v of a non-'rectangular parall'elograrn, the shingles in eachof said courses being- V positioned with 5 their corners at which their.bottom and -lateral sides meet at an obtuse angle disposed toward the`bottom and said o ne sideof the roofj the marginal portions of saidlateral sides of ,said shingles being provided with a coating ofasphaltic material having a layer of mineral granules partially embeddedtherein which rises above the front faces of the shingles, wherebyliquidsv y draining from a shingle are guided by said raised marginalportion away from the adjacent overlapping joint.

10. A roof as set forth in claim 9, each of said shingles being securedto said roof by members extending through said shingle and into saidroof and located near the corners of said shingle which meet at acuteangles.

11. A roof as set forth in claim 9, the overlapping shingles in eachcourse being secured to one another by a layerof cementing materiallocated beneath .sa-id corner.

12. A roof asset forth in claim 9, the shingles'- in onecourse beinglaid with their lower edge overlapping thev upper edge of shingles inthe next'lower course and with one side edge abutting' theA side edge ofa shingle in said lower course.

THEOPHILUS GREGORY MURPHY.

